the ebike rechargeable battery guide

The eBike Rechargeable Battery Guide Everything you need to know about PowerPacks Bosch eBike Systems 2014 Robert Bosch GmbH Bosch eBike Systems Postfach 1342 72703 Reutlingen Germany / boschebikesystems June 2014 / EN Subject to change

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Page 1: The eBike Rechargeable Battery Guide

The eBike Rechargeable Battery GuideEverything you need to know about PowerPacks

Bosch eBike Systems 2014

Robert Bosch GmbHBosch eBike Systems

Postfach 134272703 ReutlingenGermany / boschebikesystems Ju

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The PowerPacks are efficient and reliable energy suppliers for when you are on the go. At approx. 2 to 2.6 kg, they are real lightweights, with energy density (Wh/kg) that takes a leading position among ebike batteries.

Weight Saved

Weight 3

Position 4

Range 5

Charging time 10

Benefits 11

Service life 12

Handling 14

Care 18

Recycling 19

Electricity costs 19

Contents Succinctly stated

PowerPacks are the energy source of the Bosch eBike Active Line and Per formance Line systems. On the following pages, you will find tips and tricks on how to determine their range, optimize their efficiency, and maxi-mize their service life.

2 to max. 2.6 kg

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Position Balanced

When installed as a frame battery, the PowerPack is very close to the center of gravity of the bicycle and thus has a very positive effect on the handling. The rack variant is frequently used on step-through bicycles to offer as much clearance as possible when getting on and off the bike.

Range Where to from here?

PowerPacks are the fuel tanks of the ebike. State-of-the-art lithium-ion technology makes them into efficient and long- lasting suppliers of power. As an ebiker you can ride with them very economically and thus maximize the range of a rechargeable battery charge.

CadenceCadences above 50 revolutions per minute optimize the efficiency of the drive unit. In contrast, very slow pedaling is very costly in terms of energy.

WeightThe mass should be minimized by keeping the total weight of the bicycle and luggage from being unnecessarily high.

Starting & brakingAs with a car, frequent starting and stopping is less economical than long distances at a nearly constant speed.

Gear shiftingCorrect shifting also makes ebiking more efficient. It is best to start off and take inclines in a low gear. You then switch to a higher gear in accordance with the terrain and speed.

Tire pressureRolling resistance can be minimized by proper tire pressure. Tip: Always ride with the maximum allowable tire pressure.

Motor performance indicatorPay attention to the motor performance indicator of the on-board computer and adjust your riding style accordingly. A long bar means greater power consumption.

Rechargeable battery & temperatureWith decreasing temperature, the efficiency of a rechargeable battery goes down, since the electrical resistance increases. In winter you can thus expect a reduction in the normal range.

Tips and tricks for optimal range:Frame battery

Rack battery

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0 20 40 60 80 100 120 140 160 180 200 km






0 20 40 60 80 100 120 140 160 180 200 km

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Range Far-reaching technology

Ideal conditions*Flat terrain, approx. 15 km/h, no headwind, low rollingresistance, proper shifting, weight without ebike <70 kg

Favorable conditions*Slightly hilly terrain, approx. 20 km/h, light headwind,medium rolling resistance, correct shifting for the mostpart, weight without ebike 70 – 80 kg

Diffi cult conditions*Mountainous terrain, approx. 25 km/h (speed: 30 km/h), headwind, high rolling resistance, unfavorable shifting, weight without ebike > 85 kg

The above conditions are assumptions that can be both exceeded and undershot.

**  The range of the Classic+ Line is comparable to the range of the Active Line.**  The calculated ranges are typical values which can be reduced if any of the conditions

listed above worsen. The actual range of the ebikes is the responsibility of the ebikemanufacturer.

**  Average of combined use of all four modes.

Active Line range

Cruise with PowerPack 300

Cruise with PowerPack 400

Support modes, riding behavior, and external factors influence the range. For the PowerPacks, the following graphics provide an overview of the range as a function of a variety of conditions:

Ideal conditions

Favourable conditions

Diffi cult conditions

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0 20 40 60 80 100 120 140 160 180 200 km






0 20 40 60 80 100 120 140 160 180 200 km






0 20 40 60 80 100 120 140 160 180 200 km






0 20 40 60 80 100 120 140 160 180 200 km

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Cruise with PowerPack 300 Speed with PowerPack 300

Performance Line range

Speed with PowerPack 400

**  Average of combined use of all four modes.

Cruise with PowerPack 400

Ideal conditions

Favourable conditions

Diffi cult conditions

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Charging time Quickly at full charge

A charger is supplied with every ebike. One hour is required to charge the PowerPack 300 up to half, 1.5 hours for the PowerPack 400. An empty PowerPack 300 is fully charged in just 2.5 hours. A PowerPack 400 needs 3.5 hours for this.

A charge cycle is full charging of the battery with a single charge or several partial charges (such as two half-charges, for example).

No memory effectThe PowerPack with lithium-ion cells can be briefly charged at any time regardless of its charging state. Interruptions of the charging process do not harm the battery. Complete discharge is not required.

No self-dischargeEven after prolonged storage, such as during the winter, it is possible to use the rechargeable battery without recharging it. This means PowerPacks do not need to be recharged after a long break in use. For extended storage, a charge of approx. 60 % is recommended.

Long service lifePowerPacks are designed for many tours, miles, and years of service. The intelligent, electronic Bosch battery management system (BMS) protects lithium-ion batteries from excessive temperatures, overcharging, and deep discharge. The BMS checks every cell, extending the life of the battery. The makes the time from initial use to the need to replace a PowerPack very long.

Benefits The advantage of the PowerPacks

2.5 hCharging time

PowerPack 300 PowerPack 400

3.5 hCharging time

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The figure shows typical curves forenergy content over usage durationand frequency.

starke schwache Beanspruchung

Light-duty Heavy-duty Use

Age / charging cycles


gy c


nt W


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Service life Lifelines

The service life of a PowerPack is influenced mainly by the type and duration of use. Like every lithium-ion battery, a PowerPack also ages over time, even if you do not use it.

Factors that shorten the service life:•  Heavy-duty use•  Storage at over 30 °C

ambient temperature•  Prolonged storage in a completely

charged or completely discharged state

•  Parking of the ebike in the blazing sun

Factors that have a positive impacton the service life of the battery :•  Light-duty use•  Storage at optimum ambient

temperature (0 – 20 °C)•  Storage in a state of charge

of approx. 60 %

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Handling One flick of the wrist, everything under control

High-tech can be this simple. The Bosch PowerPacks rest securely in their mounts even when you are riding on uneven terrain, but they are very easy to remove for storage or charging. Simply open the lock, which serves as attachment and theft protection, and remove the battery from the mount at an angle.

It can of course be inserted again just as easily. With the low weight, handy dimensions, and precise fit of the rechargeable battery, the PowerPack can be easily and intuitively inserted. The rechargeable battery locks into its mount in a manner that is noticeable and audible, so that it rests securely on the ebike.

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Charging directly on the ebike is also very easy. You just need to insert the plugs of the charger into the charge socket in the mount and into the wall outlet. Done. The PowerPack is charged directly on the ebike.

All power packs are equipped with an ergonomic carrying handle, which makes them very easy to carry and manipulate. It allows the PowerPacks to be conveniently inserted, removed, carried, and charged.

PowerPack frame and rack batteries are maintenance free. Occasional cleaning and light greasing of the plug is still recommended, however. The batteries are also water resistant, but they should not be cleaned with high-pressure washers or immersed in water.

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Care Proper treatment

The more conscientiously you treat the PowerPack, the further it will take you.

We have a few tips and tricks in this regard:

Recycling After cycling: Recycling

The dealer takes care of environmentally sound and free disposal of Bosch PowerPacks. In this way, valuable raw materials reenter the cycle and resources are conserved. Simply take the rechargeable battery to the dealer for drop-off – on your ebike, for example.

Electricity costs Ride & save

If only everyone would use as little electrical energy as an ebiker! But even a refrigerator with 250 kWh per year consumes significantly more than an active ebike commuter with only about 40 kWh per year. But riding an ebike is good not only for the environment but also for your wallet. A full charge of a PowerPack 300 costs less than 10 cents. (Assumption: green electricity rate of 25 cents per kWh.)

ChargingThe battery should be charged under dry conditions and at room temperature.

Storage during winterStore the batteries dry and at room temperature. Between 15 °C and 20 °C is optimal. Being completely charged or completely discharged is hard on the battery. The ideal state of charge for extended periods of storage is about 50 to 60 %, or three diodes lit up on the battery indicator.

Cleaning & careTo protect the electronic components, the rechargeable battery should not be cleaned with a high-pressure cleaner. Before cleaning, remove the battery. Occasionally clean and lightly grease the plug terminals.

Winter useWhen using the battery during the winter (especially below 0 °C), we recommend waiting until briefly before departure to insert the battery, which has been charged and stored at room temperature. For frequent travel in the cold, it is advisable to use thermal protective covers.

StorageTemperatures below -10 °C and above 60 °C should be avoided.

TransportFor transport, the battery should always be taken off the ebike and safely transported in your car, for example.

InspectionUsing a diagnostic unit, the dealer can check the health status of the ebike, especially the battery, and tell you the number of charging cycles.